Jeep 200 Cherokee, Service Manual

Page: 1267 / 2119

2.5L DIESEL ENGINE
REMOVAL
(1) Disconnect both of the battery cables and
remove the battery.
(2) Mark the hinge locations on the hood for align-
ment reference during installation.
CAUTION: Wrap the appropriate size drillbit with
masking tape 1/4 inch from tip. This will prevent
damaging the hood outer panel when drilling out
the rivets retaining the hood latch cable control
assembly.
(3) Drill out the rivets retaining the hood latch
cable control assembly.
(4) Remove the hood latch assemblies from the
hood.
(5) Disconnect and remove the engine compart-
ment lamp.
(6) With assistance from another person, remove
the hood
(7) Cover both of the fenders and the grill opening
panel to prevent paint damage.
(8) Remove the battery tray.
(9) Disconnect the radiator cooling fan electrical.
(10) Remove the manual cooling fan and let set
inside of the fan shroud.
(11) If equipped, recover the refrigerant. Refer to
Group 24, Heating and Air Conditioning for the pro-
cedure.
(12) Disconnect the suction and discharge lines
and remove the lines from the vehicle.
(13) Disconnect the breather hose and remove the
air filter outlet hose from the vehicle (Fig. 15).
(14) Disconnect the oil pressure sensor electrical
connector (Fig. 15).
(15) Disconnect the EGR vacuum supply hose from
the engine (Fig. 15).
(16) Remove the coolant reservoir cap.
(17) Drain the cooling system. Refer to Group 7,
Cooling System for the procedure.
(18) Remove the upper and lower radiator hoses
from the engine.
(19) Remove the innercooler inlet and outlet hoses
from the engine (Fig. 15).
(20) Remove the coolant reservoir supply hose
from the engine (Fig. 15).
(21) On L. H. D. vehicles, disconnect the heater
core coolant supply and the brake vacuum supply
hoses from the engine.
(22) On R. H. D. vehicles, disconnect the heater
core coolant supply and the brake vacuum supply
hoses from the right side of the engine compartment.
Remove the line assembly retaining bolt and bracket
from the rear of the rocker cover and position the
assembly out of the way.
(23) Working inside of the vehicle, remove the cen-
ter console. Refer to Group 23, Body for the proce-
dure.
(24) Remove the shifter boot seal.
(25) Disconnect the shifter from the transmission
(26) Raise the vehicle on a hoist.
(27) Remove the lower fan shroud retaining bolts
and remove the lower fan shroud panel.
(28) Remove the engine ground wire (Fig. 16).
(29) Remove the right and left engine mount
throughbolt nuts only. Do not remove the bolts at
this time (Fig. 16).
(30) Drain the transmission fluid. Refer to Group
21, Transmission and Transfer Case for the proce-
dure.
(31) Mark the position of the front and rear drive-
shafts in relation to there companion flanges.
(32) Remove the front driveshaft. Refer to Group
3, Differential and Driveline for the procedure.
(33) Remove the rear driveshaft. Refer to Group 3,
Differential and Driveline for the procedure.
(34) Disconnect the exhaust system at the (3) bolt
flange (Fig. 17).
Fig. 15 LHD Engine Compartment — Diesel
1 – HEATER CORE COOLANT SUPPLY HOSES
2 – INNERCOOLER OUTLET HOSE
3 – AIR FLITER OUTLET HOSE
4 – EGR VACUUM SUPPLY HOSE
5 – OIL PRESSURE SENSOR CONNECTOR
6 – INNERCOOLER INLET HOSE
7 – COOLANT SUPPLY HOSE
9 - 18 ENGINE
XJ
REMOVAL AND INSTALLATION (Continued)